Seam forming machine

ABSTRACT

A machine for forming a double-fold, standing seam between the upstanding, abutting edges of adjacent sheets of metal roofing material. The machine comprises a plurality of rotatable forming rolls and a corresponding number of rotatable counter rolls engageable with the work for progressively forming the desired double-fold, standing seam in the sheets as the machine advances therealong. The forming rolls are mounted on slide blocks biased toward the counter rolls and the leading forming roll is manually displaceable toward and away from its associated counter roll to enable these latter rolls to initially straddle the work.

United States Patent 1 Thompson Nov. 13, 1973 SEAM FORMING MACHINE [75] Inventor: Danny W. Thompson, Niagara Falls,

[73] Assignee: Thompson Roofing Company, Inc.,

Niagara Falls, N.Y.

221 Filed: MayS, 1971 211 Appl. No.: 140,415

Primary ExaminerRichard J. Herbst Attorney-Ashlan F. Harlan [57] ABSTRACT A machine for forming a double-fold, standing seam between the upstanding, abutting edges of adjacent sheets of metal roofing material. The machine comprises a plurality of rotatable forming rolls and a corresponding number of rotatable counter rolls engageable with the work for progressively forming the desired double-fold, standing scam in the sheets as the machine advances therealong. The forming rolls are mounted on slide blocks biased toward the counter rolls and the leading forming roll is manually displace- 2,160,336 5/1939 Maxt ield 1l3/55 able toward and away from its associated counter roll 33510-191 10/1971 3/55 to enable these latter rolls to initially straddle the 2,171,297 8/1939 Zahner et al. ll3/55 work 3,487,799 l/l970 Gronlund 113/55 FOREIGN PATENTS OR APPLICATIONS 4 Claims, 12 Drawing Figures 899,446 6/1962 Great Britain 113/55 4- l m1 2 7; o /7/ J "II {I I WW7? 87 Q 55 4 83 4 SEAM FORMING MACHINE BACKGROUND OF THE INVENTION This invention related to seam forming machines and, more particularly, to mobile machines for forming seams along adjacent, upstanding edges of metal sheets.

In the art of metal roofing, it is known to employ mobile seam forming machines to interconnect adjacent metal roofing sheets or strips. Generally, these machines form a standing seam between two adjacent strips of metal roofing material, which are laid upon the roof in a side-by-side relationship. The meeting edges of the strips have upstanding longitudinal flanges abutting each other with the flange of one strip extending higher than the flange of the other. To form the standing seam, the upper portion of the longer flange is first bent to a generally horizontal position to overlie the upper edge of the shorter flange and is subsequently bent over the shorter flange so that the upper portion of the higher flange is ultimately reversely bent forming an overlying portion extending parallel to the flanges. The two flanges, together with the overlying portion of the higher flange, are pressed together to complete the standing seam.

Machines for forming such standing seams are well known. However, they are limited in their applications to forming single-fold, standing seams as described above. It is sometimes desirable to form a double fold in the standing seams of certain sheet metal roofing installations. Since the known roof-seaming machines are limited to forming single-fold, standing seams, when a double fold is desired it must be bent, at least partially, by hand. Not only is such hand operation laborious and time consuming, but it is difficult if not impossible to achieve uniform bending through the length of the finished seam.

SUMMARY OF THE INVENTION A solution to the problem described above is provided by the novel seam-forming machine of the present invention which is simple and strong in construction, low in cost, and rugged and durable in use, which is capable of forming a double fold in a standing seam, and which may be power driven.

generally speaking, the seam-forming machine of the present invention comprises a series of forming rolls, each cooperable with a corresponding counter roll, which engage the upstanding flanges of adjacent sheets of metal and form them into a standing seam having a double fold. Each of the forming rolls is differently configurated for progressively bending the flanges in the desired way. The forming rolls and the counter rolls are paired and are carried on shafts having interengaging gears secured thereto, whereby the rolls of each pair rotate in opposite directions. The forming rolls are mounted on reciprocable slides that are biased toward the counter rolls. In addition, the slide block mounting the leading forming roll is manually movable toward and away from its associated counter roll in order to enable the forming roll and its counter roll initially to straddle the abutting flanges of the metal sheets. The frictional engagement of the forming rolls and the counter rolls against the flanges propels the machine along the flanges with power from means carried by the machine.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a side elevation view of a seam-forming machine constructed in accordance with this invention;

FIG. 2 is a horizontal sectional view, on an enlarged scale, taken on the line 2-2 of FIG. 1;

FIG. 3 is a vertical sectional view taken on the plane of line 3-3 of FIG. 2;

FIG. 4 is a vertical sectional view taken on the plane of line 44 of FIG. 2;

FIG. 5 is a vertical sectional view taken on the plane of line 55 of FIG. 2;

FIG. 6 is a vertical sectional view taken on the plane of line 6-6 of FIG. 2;

FIG. 7 is a longitudinal sectional view taken on the plane of line 77 of FIG. 2;

FIG. 8 is a fragmentary horizontal sectional view, showing the means for disengaging and separating the first pair of gears;

FIGS. 9, l0, and 11 are end elevational views illustrating the formation of a double-fold, standing seam in progressive stages; and

FIG. 12 is a view similar to FIG. 11 but showing a hold-down cleat incorporated in the double-fold, standing seam.

DETAILED DESCRIPTION OF A PREFERRED EMBODIMENT Referring now in detail to the drawings, there is shown in FIG. 1 an illustrative embodiment of a metalseam forming machine, constructed in accordance with this invention and comprehensively designated 10, comprising a frame 11 mounted on a carriage 12. The latter is provided with a plurality of supporting wheels 13 for movement along a stationary surface such as a roof, for example. The wheels 13 are suitably journalled on the ends of the shafts 14 that extend laterally outwardly from crossbars 15 located at the front and rear ends of carriage 12, and are suitably attached, e.g., by screws, to the block 16, preferably formed of metal, which constitutes the major portion of the carriage. The 7 left end of the seam-forming machine 10, as viewed in FIG. 1, will be taken to the front or forward end of the machine for purposes of this description. Also, the terms top, bottom, upper, lower, and similar terms of position or direction used herein are applied only for convenience of description, with reference particularly to FIG. 1, and should not be taken as limiting the scope of this invention or necessitating any particular positioning or orientation of the machine in use.

The frame 11 is secured to the carriage 12 by suitable means, such as screws, connecting the lower portions of the side plates 11' of the frame to the block 16 on opposite longitudinal sides thereof. Extending upwardly from the frame 11 is a bar 17 having a handle 18 at its upper end for normally guiding and manipulating the machine 10. An electric motor 19 is mounted on the upper portion of frame 11 and is adapted to be connected to a suitable source of electrical power by means of a conductor cable 20. A suitable electric switch 21 having an actuating lever 22 is mounted on the bar 17 for controlling the supply of current to the motor 19. I

The electric motor 19 is connected to an output or power shaft 24 (FIGS. 2 and 5) through a suitable gear reduction mechanism 25, the shaft 24 extending downwardly through a cover 26 on the carriage 12 and having a drive gear 27 keyed to the distal end thereof. The drive gear 27 meshes with an idler gear 28 rotatably mounted on the upper end of a shaft 29 that projects downwardly through the block 16 and has a nut 31 threaded on the lower end thereof. The idler gear 28 is held in vertical position between an enlarged head 33 formed on the upper end of the shaft 29 and a bearing washer 34 disposed about the shaft 29 between the gear 28 and the block 16.

The idler gear 28 meshes with gears 35 and 35 which are diametrically disposed to the gear 28. Gear 35', in turn, operatively engages an idler gear 36 which meshes with a gear 35". The construction and mounting of idler gear 36 are identical with those of idler gear 28. It will be seen that the gears 35, 35, and 35", which are longitudinally aligned on the carriage 12, are all driven in the same direction from the drive gear 27. Since the mounting assemblies for the gears 35, 35' and 35" are identical in construction, it is believed that a detailed description of only one such assembly will here suffice, it being understood that in each assembly the same reference characters will designate identical elements.

Each of these gears 35, 35' and 35" is mounted on the reduced diameter, upper end portion 37 of a rotatable shaft 38 journalled for rotation in a sleeve bearing 39 mounted in the block 16. The gear is secured for rotation with the shaft 38 by a key 40 and is held against axial displacement between a nut 41 threaded on the end portion 37 of the shaft 38 and a bearing washer 42 below. the gear. The other end of the shaft 38 is provided with an integral backup or counter roll, the counter rolls associated with the gears 35, 35 and 35" being numbered respectively, 43, 43', and 43". A suitable bearing washer 44 is provided between each counter roll and the block 16.

The gears 35 and 35, respectively, mesh directly with gears 45 and 45 and consequently when the former rotate, the latter are turned in the opposite direction. Since the gears 45 and 45' form parts of assemblies that are identical in construction, a detailed description of only one assembly, i.e. the one for gear 45, is believed to be sufficient here. In the drawings the identical elements forming portions of the assemblies for gear 45 are given the same numeral but with a prime.

The gear 45 is mounted on the reduced diameter, upper end portion 47 of a rotatable shaft 48 that is journalled for rotation in a sleeve bearing 49. The latter extends through a slide or block 50 that is mounted in a cavity 51 in the side of the block 16 for lateral, reciprocating motion therein. The gear 45 is secured for rotation to the upper end portion 47 of the shaft 48 by means of an interengaging key 52 and is held against axial displacement between a nut 53 on the portion 47 and a bearing washer 54 between the gear and the slide 50. The slide 50 is guided in its reciprocating movement in the cavity 51 by removable guide rods 55 arranged adjacent the corners of the slide and projecting inwardly from the outer face of block- 16 into the cavity 51. The guide rods are received partially in guide grooves 56 provided in the slide and partially in the guide grooves 57 formed in the block 16, as best seen in FIG. 7. The rods are retained in place by the lower portion of one of the side plates 11'. The slide 50 is acted upon by a plurality of coil compression springs 58 to bias the slide and its associated gear 45 into engagement with the corresponding gear 35. The springs 58 bear at their inner ends against the face of the slide 50 and are received at their outer ends in recesses 59 formed in the block 16.

The gear 45" is mounted on the upper end portion 47" of the rotatable shaft 48 and is keyed thereto by key 52" for rotation together. The shaft 48" is journailed in a sleeve bearing 49" which extends through a slide 50" mounted in a recess or cavity 51" in the side of block 16 for lateral, reciprocating motion. As with the mounting of gear 45, the gear 45" is held on its shaft by a nut 53" and is provided with a bearing washer 54". Guiding means for the slide 50" is provided by removable guide rods 55", the construction and arrangement of which are like those of rods 55, that extend to the outside of the cavity 51".

Coiled compression springs 60 which bear at their inner ends against the face of the slide 50" and are received at their other ends in recesses 61 formed in a reciprocatable plunger comprehensively designated 62 are provided for biasing the slide 50" and the assembly carried thereby toward said gear 35" and counter roll 43". The two lower springs 60, as shown in FIG. 8, surround studs 63 that extend through the plunger 62 and are threaded into the slide 50" for manually moving it as hereinafter described.

The plunger 62 is slidably mounted for reciprocation in the cavity 51" and in a housing 64 suitably secured to the side of the block 16, as by means of screws 65 extending through lateral flanges 66 of the housing. The housing 64 comprises an upper plate 67, a lower plate 68, and a pair of side plates 69, all projecting outwardly from the side of the block 16 and defining a horizontal port 70 therebetween which is aligned with the cavity 51".The inner portion of the port 70 is identical in cross section with the cavity 51" but the outer portion is less in height. The plunger 62 is provided with an extension 72 of reduced thickness slidably received in the outer portion of port 70 and having a vertical port 73 therethrough defined by inner and outer planar surfaces 74 and 75 (FIG. 3). A rotatable shaft 76 extends vertically through the upper plate 67 of housing 64, the port 73 and the lower plate 68. The upper end of the shaft 76 is provided with an end portion 77 of reduced diameter having a hub 78, mounted thereon by a key 80, carrying a handle 79 and held in bearing contact against the outer surface of the plate 67 by a nut 81 threaded on the end portion 77.

The shaft 76 is provided with an eccentric or cam 82 disposed in the opening 73 between the upper plate 67 and the lower plate 68. The cam 82 bears against the vertical surfaces 74 and 75 of the port 73 and is adapted to reciprocate the plunger 62 transversely toward and away from the slide 50" when the handle 79 is moved through a horizontal are. As shown in FIG. 3, the cam 82 is rotated to such a position that the high portion thereof bears against the surface 74 to force the plunger 62 inwardly thereby compressing the springs 60 and urging the slide 50" inwardly, causing the gear 45" to mesh with the gear 35'. In the diametrically opposite position of the cam 82 as shown in FIG. 8, the high portion of the eccentric 82 bears against the vertical surface 75 thereby moving the plunger 62 outwardly into the housing 64 and, by means of the studs 63, moving the slide 50" and gear 45" outwardly.

Forming rolls 83, 84, and 85 are integrally formed with the lower ends of the shafts that carry gears 45, 45, and 45" respectively, whereby rotation of the gears will rotate the forming rolls in a direction opposite to that of the counter rolls 43, 43', and 43".

The metal-seam forming machine of the present invention is especially adapted for forming a doublefold, standing seam on the abutting upstanding flanges of adjacent elongated sheets or strips of metal roofing material. Referring now to FIGS. 9-12 of the drawings, it will be seen that a pair of adjacent metal roofing strips 86 are laid in a side-by-side relation on the roof substructure 87. Upstanding longitudinal flanges 88 and 89, the former being wider than the latter, are provided along the longitudinal edges of each strip 86 and the flanges 88 and 89 of adjacent strips are disposed in abutting relation. The upper portions of the flanges 88 and 89 are bent together at right angles as at 90and the extra width of the flange 88 is bent downwardly as at 91 over the free edge of the flange 89 and slightly back toward the main portions of the flanges to provide a somewhat retrogade edge portion 92. The flanges 88 and 89 are formed on the strips 86 and bent to the shapes shown in FIG. 9 prior to laying the strips on the roof for seam formation by the machine. The flanges 88 and 89 are then progressively further bent into the shapes shown in FIGS. 10 and l 1 by forming rolls of the seam-forming machine 10 as the machine progresses along the sheet juncture to provide between adjacent strips a double-fold, standing seam, generally designated 93.

In order to secure the metal strips 86 to the roof substructure 87 without puncturing the strips, with consequent danger of leaks, a plurality of narrow cleats or clips 94 are employed, at longitudinally spaced intervals along each joint or seam. Each cleat 94 is preferably of thin metal and comprises a horizontal portion 95 which is secured to the roof substructure 87 by a nail 96. Each cleat 94 also comprises a 90 flange 97 that extends upwardly between the flanges 88 and 89 of adjacent strips 86 and is bent along with flanges 88 and 89 to form the double-fold, standing seam 93 as depicted in FIG. 12. If desired, the free end of the horizontal portion 95 may be reversely bent to overlie the head of the nail 96, as shown in FIG. 12, and ensure its remaining in place.

As pointed out above, a series of forming rolls 83, 84, and 85 are carried on the lower ends of shafts 48, 48', and 48". These, in cooperation with the counter rolls 43, 43, and 43", respectively, progressively deform the flanges 88 and 89 of adjacent metal strips 86 to produce the double-fold, standing seam joint 93. A bearing washer 98 is provided between each of the forming rolls and the lower face of the slide by which it is carried. The configurations of the forming rolls are important since upon them depends the proper bending of the flanges to achieve the double fold. They are described below in the order of functioning.

Forming roll 85 is essentially cylindrical but is provided adjacent its upper end with a deep annular groove 100 having parallel sides. Forming roll 84 has a lower cylindrical portion 102 and an upper, outwardly bevelled portion 103, the two portions being separated by a thin annular flange or rib 104. The third forming roll 83 is cylindrical in shape. The shapes of the rolls are best seen in FIGS. 3, 4, 6, and 7 and the latter figure illustrates the action of the rolls in progressively forming the seam as the machine 10 moves along a joint between two adjacent metal sheets.

When the machine 10 is to be used, it is placed at one end of the abutting flanges 88 and 89 of two adjacent metal strips 86 which are to be connected together by a double-fold, standing seam. The handle 79 is manipulated to swing the high portion of the eccentric or cam 82 against the internal surface of the port 73, as shown in FIG. 8, thereby moving the plunger 62 outwardly and with it the slide 50", drawn by the studs 63. The forming roll is thereby moved away from the counter roll 43" so that such rolls can straddle and embrace the ends of bent flanges 88 and 89, assembled as shown in FIG. 9. After the machine 10 is properly positioned relative to the flanges 88 and 89, the handle 79 is again manipulated to being the high portion of the cam 82 against the internal surface 74 of the port 73 thereby moving the plunger 62 inwardly and permitting the springs 60 to move the slide 50" inwardly thus forcing the forming roll 85 against the flanges with the bend 91 of the flange 88 entering the peripheral groove of the roll and being flattened therein to the shape shown in FIG. 10 and FIG. 3.

With the conductor cable 20 connected to a suitable source of electrical power (not shown), the switch 21 is actuated to energize the motor 19 and rotate the output shaft 24 and the drive gear 27. All the gears 35, 35 35", 45, 45, and 45" are then rotated from the drive gear 27 through the idler gears 28 and 36. The frictional engagement of the rotating forming rolls 83, 84, and 85, and the counter-rotating, counter rolls 43, 43, and 43" with the upstanding flanges 88 and 89 causes the machine to be driven relative to such flanges. The sequence of operation by the rolls is illustrated in FIG. 7 and the form of the seam in the abutting flanges at different stages of development is shown in FIGS. 912, inclusive.

As pointed out above, FIG. 9 shows the arrangement of the flanges before engagement by rolls 85 and 43". FIG. 10 shows the partially formed seam as developed by rolls 85 and 43" before bending by rolls 84 and 43' to the position shown in FIG. 4 and FIG. 11 shows the completed double-fold, standing seam 93 after operation of the rolls 43 and 83. FIG. 12 is essentially like FIG. 11 except that it shows the appearance of the seam at a point where a cleat is provided for holding the sheets to the roof, the upstanding flange on the cleat being included in the seam.

It will be evident that the machine of the present invention functions well and conveniently in forming double-fold, standing seams on roofing sheets. The seams are firmly locked and the double fold obviates the possibility of leakage thus ensuring a satisfactory roof. Because of the use of cleats for holding the sheets down, leakage around nail holes is also prevented.

A preferred embodiment of this invention having been described and illustrated in detail, it is to be understood that numerous modifications thereof may be made without departing from the broad spirit and scope of this invention, as defined in the appended claims.

I claim:

1. A machine for forming a double-fold, standing seam in abutting upstanding edges of adjacent metal sheets in one pass comprising: a carriage; rolling means for supporting said carriage; forming means, said forming means consisting essentially of three pairs of cooperating forming rolls and counter rolls mounted and longitudinally spaced on said carriage for successive engagement with portions of said abutting edges of said metal sheets; means resiliently biasing said forming rolls toward said counter rolls; and means, including interengaging gears associated with and rotating with each of said rolls, for causing rotation of said forming rolls and said counter rolls in opposite directions; all of said counter rolls being cylindrical in shape and said forming rolls, in order of operation as said seam is formed, being shaped (a) as a cylinder having adjacent its upper end a deep annular groove with parallel sides, (b) as a cylinder having an outwardly bevelled upper portion and an annular flange between said upper portion and the lower portion thereof, and (c) as a plain cylinder, whereby said abutting edges are progressively folded; and the frictional engagement between said rolls and said abutting edges propelling said carriage along said sheets as said seam is formed.

2. A machine as set forth in claim 1 wherein each of said forming rolls is mounted on one end of a shaft, each of said shafts is carried by a slide mounted in said carriage for transverse reciprocating movement, and said resiliently biasing means acts on said slides.

3. A machine as set forth in claim 2 wherein means is provided for manually displacing one forming roll toward and away from its associated counter roll.

4. A machine as set forth in claim 3 wherein said means for manually displacing one forming roll comprises studs connected to the slide carrying said roll and means for moving said studs. 

1. A machine for forming a double-fold, standing seam in abutting upstanding edges of adjacent metal sheets in one pass comprising: a carriage; rolling means for supporting said carriage; forming means, said forming means consisting essentially of three pairs of cooperating forming rolls and counter rolls mounted and longitudinally spaced on said carriage for successive engagement with portions of said abutting edges of said metal sheets; means resiliently biasing said forming rolls toward said counter rolls; and means, including interengaging gears associated with and rotating with each of said rolls, for causing rotation of said forming rolls and said counter rolls in opposite directions; all of said counter rolls being cylindrical in shape and said forming rolls, in order of operation as said seam is formed, being shaped (a) as a cylinder having adjacent its upper end a deep annular groove with parallel sides, (b) as a cylinder having an outwardly bevelled upper portion and an annular flange between said upper portion and the lower portion thereof, and (c) as a plain cylinder, whereby said abutting edges are progressively folded; and the frictional engagement between said rolls and said abutting edges propelling said carriage along said sheets as said seam is formed.
 2. A machine as set forth in claim 1 wherein each of said forming rolls is mounted on one end of a shaft, each of said shafts is carried by a slide mounted in said carriage for transverse reciprocating movement, and said resiliently biasing means acts on said slides.
 3. A machine as set forth in claim 2 wherein means is provided for manually displacing one forming roll toward and away from its associated counter roll.
 4. A machine as set forth in claim 3 wherein said means for manually displacing one forming roll comprises studs connected to the slide carrying said roll and means for moving said studs. 